Control system for thermal module in vehicle

ABSTRACT

A climate control device includes a first and a second thermal module. The first module is configured to provide climate conditioned air to a first portion of a seat. The second module is configured to provide climate conditioned air to a second portion of the seat. A control system is provided for controlling the climate control device. The control system includes an input device for providing a set point for the system. A first control unit of the control system is provided for the first thermal module and a second control unit is provided for the second thermal module.

PRIORITY INFORMATION

This application claims the priority benefit under 35 U.S.C. § 119(e) ofProvisional Application 60/637,725, filed Dec. 20, 2004.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to climate control. More specifically, thisinvention relates to climate control of a seat.

2. Description of the Related Art

Temperature modified air for environmental control of living or workingspace is typically provided to relatively extensive areas, such asentire buildings, selected offices, or suites of rooms within abuilding. In the case of vehicles, such as automobiles, the entirevehicle is typically cooled or heated as a unit. There are manysituations, however, in which more selective or restrictive airtemperature modification is desirable. For example, it is oftendesirable to provide an individualized climate control for an occupantseat so that substantially instantaneous heating or cooling can beachieved. For example, an automotive vehicle exposed to the summerweather, where the vehicle has been parked in an unshaded area for along period, can cause the vehicle seat to be very hot and uncomfortablefor the occupant for some time after entering and using the vehicle,even with normal air conditioning. Furthermore, even with normalair-conditioning, on a hot day, the occupant's back and other pressurepoints may remain sweaty while seated. In the winter, it is highlydesirable to have the ability to warm the seat of the occupant quicklyto facilitate the occupant's comfort, especially where the normalvehicle heater is unlikely to warm the vehicle's interior as quickly.

For such reasons, there have been various types of individualizedclimate control systems for vehicle seats. Such climate control systemstypically include a distribution system comprising a combination ofchannels and passages formed in the back and/or seat cushions of theseat. A thermal module conditions the climate of the air and deliversthe conditioned air to the channels and passages. The climateconditioned air flows through the channels and passages to cool or heatthe space adjacent the surface of the vehicle seat.

There are, however, drawbacks with existing climate control systems forseats. For example, some climate control systems are not easilyintegrated into existing seat construction methods. Such systems requirea significantly greater number of parts as compared to existingautomotive seats, and often require complex mechanical parts and/orelectrical connections. In the past, this has resulted in increasedcosts for individualized occupant cooling in automobiles.

In particular, many advanced climate control systems allow the user tocontrol individually the climate for each seat in the vehicle. In somesystems, the user may also vary the climate between different portionsof the seat. For example, the user may vary the climate settings betweenthe seat cushion and the back cushion. In one arrangement, the userinputs the desired climate setting through an input or control switch.An intermediate control module interprets the signal from the controlswitch and generates control signals for a pair thermal modules, whichare individually associated with the seat and back cushions. A set ofpower, control and signal wires extend between the thermal modules andthe intermediate control module. These wires are used to control anddrive the thermal modules to achieve the desired climate setting. Incertain arrangements, seven or more wires may extend between theintermediate control modules and each thermal module. For one seat,therefore, there may be over fourteen wires extending between theintermediate control module and the climate control devices. These wiresrequire a significant amount of space and complicate the design andlayout of the climate control system.

Thus, there is a need for an improved climate control apparatus for aclimate control system for seats.

SUMMARY OF THE INVENTION

Accordingly, one aspect of the present invention involves a device forthermally conditioning and moving a fluid. The device includes athermoelectric device to convert electrical energy into thermal energyproducing a temperature change in response to an electrical currentbeing applied thereto. A fluid transfer device produces a fluid flowthat is in thermal communication with the thermoelectric device so thatthe thermal energy generated by the thermoelectric device is transferredto the fluid flow. A housing has an outlet and an inlet through whichthe fluid flow is directed. The thermoelectric device and the fluidtransfer device are positioned at least partially within the housing. Asensor is configured to provide a temperature signal that is indicativeof the temperature of the fluid flow. A control unit is coupled to thehousing and is operatively connected to the sensor. The control unit isconfigured to receive a set point signal that is indicative of a desiredtemperature of the fluid flow based and configured to control thethermoelectric device and the fluid transfer device.

Another aspect of the present invention comprises a device for thermallyconditioning and moving a fluid. The device includes a thermoelectricdevice to convert electrical energy into thermal energy producing atemperature change in response to an electrical current being appliedthereto. A fluid transfer device produces a fluid flow that is inthermal communication with the thermoelectric device. A sensor isconfigured to provide a temperature signal that is indicative of thetemperature of the fluid flow. A control unit is operatively connectedto the sensor. The control unit is configured to receive a set pointsignal that is indicative of a desired temperature of the fluid flowand, based upon the set point signal and the temperature signal, tocontrol the thermoelectric device and the fluid transfer device. Thecontrol unit is also configured to receive a second temperature signalfrom a second sensor. The second temperature signal is indicative of thetemperature of the fluid flow within a second device for thermallyconditioning and moving a fluid. The control unit is configured tocontrol the second device based upon the set point signal and the secondtemperature signal so as to control the temperature and fluid flowwithin the second device.

Another aspect of the present invention comprises a climate controlledseat assembly that includes a seat cushion having a ventilation system.A main control unit is configured to generate a mode signal for the seatassembly. A first thermal module is configured to thermally conditionair at a first portion of the ventilation system. A first sensor isconfigured to sense a condition of the first thermal module and toprovide a condition signal corresponding to the sensed condition. Afirst control unit is operatively connected to the main control unit,the first sensor and the first thermal module. The first control unit isconfigured to drive the first thermal unit based upon the mode signaland the condition signal. A second thermal module is configured tothermally condition air at a second portion of the ventilation system. Asecond control unit is provided for the second thermal module. The firstcontrol unit is configured to control the second control unit based uponthe mode signal and the condition signal.

Another aspect of the present invention involves a method for thermallyconditioning a space adjacent a seat assembly. In the method, an inputsignal from an input device is transmitted to a control unit of a firstthermal module. The first thermal module is controlled based at least inpart upon the input signal to deliver thermally conditioned air to afirst portion of a seat assembly. A control signal is transmitted fromthe control unit of the first thermal module to a control unit of asecond thermal module so as to control the second thermal module anddeliver thermally conditioned air to a second portion of the seatassembly based at least in part upon the input signal from the inputdevice.

Another aspect of the present invention involves a climate controlledseat assembly that comprises a seat cushion, a main control unit, afirst thermal module and a second thermal module. The seat cushionincludes a ventilation system having a first portion and a secondportion. The main control unit is configured to generate a mode signalfor the seat assembly. The first thermal module is configured tothermally condition air that is delivered to the first portion of theventilation system. The first thermal module comprises a first sensorconfigured to sense a condition of the first thermal module and toprovide a condition signal corresponding to the sensed condition and afirst control unit that is operatively connected to the main controlunit, the first sensor and the first thermal module. The first controlunit is configured to drive the first thermal unit based upon the modesignal and the condition signal of the first thermal module. The secondthermal module hat is configured to thermally condition air that isdelivered to the second portion of the ventilation system. The secondthermal module comprises a second sensor configured to sense a conditionof the second thermal module and to provide a condition signalcorresponding to the sensed condition and a second control unit that isoperatively connected to the main control unit, the second sensor andthe second thermal module. The second control unit is configured todrive the second thermal unit based upon the mode signal and thecondition signal of the second thermal module.

Further features and advantages of the present invention will becomeapparent to those of ordinary skill in the art in view of the detaileddescription of preferred embodiments which follow, when consideredtogether with the attached drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a vehicle seat assembly, which includesa climate control system that is configured in accordance with apreferred embodiment of the present invention;

FIG. 2 is a side view of the vehicle seat assembly of FIG. 1;

FIG. 2A is a cross-sectional view of the vehicle seat assembly of FIG. 1taken along line 2A-2A of FIG. 2.

FIG. 2B is a cross-sectional view of the vehicle seat assembly of FIG. 1taken along line 2B-2B of FIG. 2.

FIG. 3 is a front view of the vehicle seat assembly of FIG. 1 with acovering of the seat assembly removed;

FIG. 4 is a schematic illustration of the vehicle seat assembly andclimate control system of FIG. 1;

FIG. 5 is a perspective view of a thermal module of the climate controlsystem of FIG. 1;

FIG. 6 is a schematic illustration of another embodiment of a climatecontrol system; and

FIG. 7 is a schematic illustration the vehicle seat assembly of FIG. 1with a modified embodiment of a climate control system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIGS. 1 and 2 illustrate an exemplary embodiment of a seat assembly 30that comprises a seat 32 and a backrest 34. The seat assembly 30includes a climate control system 36, which will be described in moredetail below with reference to FIG. 4.

When an occupant sits in the seat assembly 30, the occupant's seat islocated generally in a seat area 40 of the seat portion 32 and at leasta portion of their legs are supported by a thigh area 42 of the seatportion 32. In this embodiment, a rear end 44 of the seat portion 32 iscoupled to a bottom end 46 of the backrest portion 34. When the occupantsits in the seat assembly 30, the occupant's back contacts a frontsurface 48 of the backrest portion 34 and the occupant's seat and legscontact a top surface 50 of the seat portion 32. The surfaces 48, 50cooperate to support the occupant in a sitting position. The seatassembly 30 can be configured and sized to accommodate occupants ofvarious size and weight.

In the illustrated embodiment, the seat assembly 30 is similar to astandard automotive seat. However, it should be appreciated that certainfeatures and aspects of the seat assembly 30 described herein may alsobe used in a variety of other applications and environments. Forexample, certain features and aspects of the seat assembly 30 may beadapted for use in other vehicles, such as, for example, an airplane, aboat, or the like. Further, certain features and aspects of the seatassembly 30 may also be adapted for use in stationary environments, suchas, for example, a chair, a sofa, a theater seat, a mattress, and anoffice seat that is used in a place of business and/or residence.

With continued reference to FIGS. 1 and 2, the backrest 34 has a frontside 54, a rear side 56, a top side 58 and a bottom side 60. Thebackrest 34 includes a pair of sides 57, 59 extending between the topside 58 and bottom side 60 for providing lateral support to the occupantof the seat assembly 30. A lumbar region 62 of the backrest 34 isgenerally positioned between the sides 57, 59 of the backrest 34 nearthe seat portion 32.

In a similar manner, the seat portion 32 has a front side 64, a rearside 66, a top side 68 and a bottom side 70. The seat portion 32 alsoincludes a pair of sides 69, 71, which extending from the rear side 66and the front side 64 for providing lateral support to the occupant ofthe seat assembly 30. In one embodiment, the seat assembly 30 is securedto a vehicle by attaching the bottom side 70 of the seat portion 32 tothe floor of a vehicle.

FIG. 2A is a cross-sectional view of a portion of the backrest 34. Asshown, the backrest 34 is generally formed by a cushion 72, which iscovered with an appropriate covering material 74 (e.g., upholstery). Thecushion 72 is typically supported on a metallic frame (not shown). Insome embodiments, springs may be positioned between the frame and thecushion 72. The frame provides the seat assembly 30 with structuralsupport while the cushion 72 provides a soft seating surface. Thecovering material 74 provides an aesthetic appearance and soft feel tothe surface of the seat assembly 30. The seat portion 32 may beconstructed in a similar manner as the backrest 34.

FIG. 3 illustrates the seat assembly with the covering 74 removedthereby exposing the cushion 72. The cushion 72 can be a typicalautomotive seat cushion foam or other types of materials with suitablecharacteristics for providing support to an occupant. Such materialsinclude, but are not limited to, closed or open-celled foam.

As shown in FIG. 3, the backrest 34 of the seat assembly 30 is providedwith a backrest fluid distribution system 76A. The distribution system76A comprises an inlet passage 78A through from the front side 54 to therear side 56 of the seat cushion 72. (See also FIG. 2A). Thedistribution system 76A also includes at least one, and often, aplurality of channels 80A, which extend from the inlet passage 78A.

As mentioned above, the cushion 72 may be formed from a typicalautomotive cushion material, such as, for example, an open or closedcell foam. In one embodiment, the cushion 72 is made of foam that ispre-molded to form the passage 78A and/or the channels 80A. In anotherembodiment, the passage 78A and/or the channels 80A may be formed bycutting foam out of the seat cushion 72.

With reference back to FIG. 2A, the channels 80A are covered by a scrim81A to define distribution passages 82A for transporting air through theseat assembly 30. The scrim 81A includes one or more openings 84A fordelivering air to and/or from the distribution passages 82A. The scrim81A may be formed of a material similar to the cushion 72. In theillustrated embodiment, the scrim 81A is attached to the cushion 72 in amanner that limits leakage between the scrim 81A and cushion 72 therebydirecting the flow of air through the openings 84A. In one embodiment,an adhesive is used to attach the scrim 81A to the cushion 72. In otherembodiments, a heat stake or fasteners may be used.

With continued reference to FIG. 2A, a distribution layer 86A isdisposed between the scrim 81A and the seat covering 74. Thedistribution layer 86A spreads the air flowing through the openings 84Aalong the lower surface of the covering 74. To permit airflow betweenthe distribution layer 86A and the spaces proximal to the front surface48 of the backrest 34, the covering 74 may be formed from anair-permeable material. For example, in one embodiment, the covering 74comprises an air-permeable fabric made of natural and/or syntheticfibers. In another embodiment, the covering is formed from a leather, orleather-like material that is provided with small openings or apertures.

With reference to FIGS. 2B and 3, the seat 32 of the seat assembly 30 isprovided with a seat cushion fluid distribution system 76B. The seatdistribution system 76B also comprises an inlet passage 78B through fromthe top side 68 to the bottom side 70 of the seat cushion 72. As withthe backrest distribution system 76A, the seat distribution system 76Balso includes at least one, and often, a plurality of channels 80B,which extend from the inlet passage 78B. These channels 80B may beconfigured as described above.

In the seat distribution system 76B, the channels 80B are also coveredby a scrim 81B to define distribution passages 82B for transporting airthrough the seat assembly 30. The scrim 81B includes one or moreopenings 84B for delivering air to and/or from the distribution passages82B. As described above, the scrim 81B may be formed of a materialsimilar to the cushion 72 and is preferably attached to the cushion 72in a manner that limits leakage between the scrim 81B and cushion 72. Adistribution layer 86B is disposed between the scrim 81B and the seatcovering 74.

As will be explained in more detail below, in one embodiment,conditioned air is delivered to the distribution passages 82A, 82Bthrough the inlet passages 78A, 78B. The air then flows through theopenings 84A, 84B and into the distribution layer 86A, 86B. The air isthen directed through the covering 74 to a space adjacent to the frontsurface 48 of the backrest 34 or the top surface 50 of the seat 32. Inanother embodiment, the climate control system 36 is used to remove air,which is adjacent to the front surface 48 of the backrest 34 and/or thetop surface 50 of the seat 32. In such an embodiment, the air iswithdrawn through the covering 74 and into the distribution layers 86A,84B. The air is then withdrawn through the openings 84A, 84B, into thedistribution passages 82A, 82B and through the inlet passage 78A, 78B.

Given the goal of distributing air through the cushion 72 and along thecovering 74, those of skill in the art will recognize that thedistribution systems 76A, 76B for the backrest 34 and the seat 32 may bemodified in several different manners. For example, the shape and/ornumber of channels 80A, 80B may be modified. In other embodiments, thescrim 81A, 81B and/or distribution passages 82A, 82B may be combinedand/or replaced with other components configured for similar functions.In yet another embodiment, a separate insert may be positioned withinthe channels 80A, 80B for distributing the air. See e.g., co-pendingU.S. patent application Ser. No. 10/853,779, filed May 25, 2004, theentire contents of which are hereby incorporated by reference herein. Inother embodiments, the distribution systems 76A, 76B or portions thereofmay be combined with each other.

FIG. 4 is a schematic illustration of the climate control system 36. Inthe illustrated embodiment, the climate control system includes a backthermal module 92A and seat thermal module 92B. As will be explainedbelow, both thermal modules 92A, 92B are configured to provideconditioned air (and/or to remove air in some embodiments) to thedistribution systems 76A, 76B described above. In this manner, thethermal modules 92A, 92B provide a fluid flow to either warm or cool thefront surface 48 of the backrest 34 and the top surface 50 of the seatportion 32 respectively. Specifically, the climate control apparatus 36preferably provides conditioned air that is either heated or cooledrelative to the temperature of the front surface 48 of the back rest 32and the top surface 50 of the seat 32.

In the illustrated embodiment, the thermal modules 92A, 92B preferablyeach include a thermoelectric device 94A, 94B for temperatureconditioning (i.e. selectively heating or cooling) the fluid flowingthrough the device 94A, 94B. A preferred thermoelectric device 94A, 94Bis a Peltier thermoelectric module, which is well known in the art. Theillustrated thermal modules 92A, 92B preferably also include a main heatexchanger 96A, 96B for transferring or removing thermal energy from thefluid flowing through the modules 92A, 92B and to the distributionsystems 76A, 76B. Such fluid is transferred to the distribution systems76A, 76B through conduits 98A, 98B (see e.g., U.S. application Ser. No.10/973,947, filed Oct. 25, 2004, which is hereby incorporated byreference herein). The modules 92A, 92B also preferably include a wasteheat exchanger 100A, 100B that extends from the thermoelectric device94A, 94B generally opposite the main heat exchanger 96A, 96B. A pumpingdevice 102A, 102B is preferably associated with each thermal module 92A,92B for directing fluid over the main and/or waste heat exchangers 96A,96B, 100A, 100B. The pumping devices 102A, 102B may comprise anelectrical fan or blower, such as, for example, an axial blower and/orradial fan. In the illustrated embodiment, a single pumping device 102A,102B may be used for both the main and waste heat exchangers 96A, 96B,100A, 100B. However, it is anticipated that separate pumping devices maybe associated with the waste and heat exchanges 96A, 96B, 100A, 100B.

It should be appreciated that the thermal modules 92A, 92B describedabove represents only one exemplary embodiment of a device that may beused to condition the air supplied to the distribution systems 76A, 76B.Any of a variety of differently configured thermal modules may be usedto provide conditioned air. Other examples of thermal modules that maybe used are described in U.S. Pat. Nos. 6,223,539, 6,119,463, 5,524,439or 5,626,021, which are hereby incorporated by reference in theirentirety. Another example of such a thermal module is currently soldunder the trademark Micro-Thermal Module™ by Amerigon, Inc. In anotherexample, the thermal module may comprise a pump device without athermoelectric device for thermally conditioning the air. In such anembodiment, the pumping device may be used to remove or supply air tothe distribution system 76A, 76B. In yet another embodiment, the thermalmodules 92A, 92B, may share one or more components (e.g., pumpingdevices, thermoelectric devices, etc.) with the vehicles general climatecontrol system.

In operation, fluid in the form of air can be delivered from the thermalmodules 92A, 92B, through the conduits 98A, 98B to the distributionsystems 76A, 76B. As described above, the air flows through the passages82A, 82B, into the openings 84A, 84B and then along the distributionlayer 86A, 86B and through the covering 74. In this manner, conditionedair can be provided to the front surface 48 of the backrest 34 and thetop surface 50 of the seat 32.

In a modified embodiment, air from within the passenger compartment ofthe automobile can be drawn through the covering 74, into thedistribution layer 86A, 86B and through the openings 84A, 84B. The airthen can flow through the distribution passages 82A, 82B, into the inletpassage 78A, 78B and then into the conduit 98A, 98B. In this manner, theclimate control system 36 can provide suction so that air near thesurface of the seat assembly 30 is removed.

A control system 104 for the climate control system 36 will now bedescribed with continued reference to FIG. 4. As shown, the controlsystem 104 includes a user input device 106 through which the user ofthe climate control system 36 can provide a control setting or set modefor the climate control system 36. The control setting can comprise aspecific temperature setting (e.g., 65 degrees), a more generaltemperature setting (e.g., “hot” or “cold”), and/or a setting for thepumping device (e.g., “high,” “medium,” or “low”). Depending upon thedesired configuration, the input device 106 may include any of a varietyof input devices, such as, for example, dials, buttons, levers,switches, etc. The user input device 106 may also include a user outputthat provides visual or audio indicia of the control setting (e.g., anLED display).

With continued reference to FIG. 4, the input device 106 is operativelyconnected to a seat control module 110, which in the illustratedembodiment is associated with the seat thermal module 92B. The seatcontrol module 110 is, in turn, operatively connected to the pumpingdevice 102B and the thermoelectric device 94B. In addition, atemperature sensor 112 is provided to measure the temperature of thefluid conditioned by the thermoelectric device 94B. The temperaturesensor 112 is operatively connected to the seat control module 110. Theseat control module 110 is preferably also operatively connected to apower source 114 and a ground source 116 and includes an appropriatepower control unit to provide sufficient electrical capacity to operateall of the aforementioned devices (92B, 94B, 112) of the seat thermalmodule 92B. The seat control module 110 preferably also has a controllerthat is configured to receive the occupant inputs from the input device106 and the temperature information from the temperature sensor 112.From this information, the seat control module 110 is configured to makeadjustments to the operation of the thermoelectric device 94B and thefluid pump 102B according to a predetermined logic designed to ensureoccupant comfort and to protect against system damage. Those of skill inthe art will appreciate that the seat control module can comprise ahard-wired feed back control circuit, a dedicated processor or any othercontrol device that can be constructed for performing the steps andfunctions described herein. In additions, the controller within the seatcontrol module 110 may be combined or divided as deemed appropriate.

Various components are described as being “operatively connected” to thecontrol unit. It should be appreciated that this is a broad term thatincludes physical connections (e.g., electrical wires) and non-physicalconnections (e.g., radio or infrared signals). It should also beappreciated that “operatively connected” includes direct connections andindirect connections (e.g., through an additional intermediate device).

The seat control module 110 optionally may also be configured to receivea signal from a vehicle control device 118 that indicates whether thevehicle's ignition has been turned on. In this manner, the seat controlmodule 110 may be configured to allow operation of the thermal module92B only if the vehicle's engine is running.

With continued reference to FIG. 4, the backrest thermal module 92Aincludes a backrest control module 120. As shown, the backrest controlmodule 120 is operatively connected to the thermoelectric device 94A andthe fluid pump 102A for the backrest 34. The backrest control module 120is connected to the power source 114 and the ground source 116 andincludes a controller configured to provide sufficient electricalcapacity to operate the thermoelectric device 94A and the fluid pump102A. As will be explained below, the backrest control module 120 isconfigured to receive a control signal from the seat control module 110.From this information, the backrest control module 120 operates thethermoelectric device 94B and the fluid pump 102B to ensure occupantcomfort and safety, and protect against system damage. Those of skill inthe art will appreciate that the backrest control module 120 cancomprise a hard wired feed back control circuit, a dedicated processoror any other control device that can be constructed for performing thesteps and functions described herein.

In the illustrated embodiment, a communication line 122 operativelyconnects the backrest control module 120 to the seat control module 110.In one embodiment, the seat control module 110 is configured to receivethe inputs from the input device 106 to make adjustments to theoperation of the thermoelectric device 94A and the fluid pump 96A in thebackrest thermal module 92A according to a predetermined logic designedto ensure occupant comfort and safety, and protect against systemdamage. The control signals generated by the seat control module 110 aretransmitted to the backrest control module 120 through the communicationline 122.

The illustrated embodiment optionally includes a backrest temperaturesensor 124 for measuring the temperature of the fluid that has beenthermally conditioned by the backrest thermal module 92A. Theinformation from this temperature sensor 124 may optionally betransmitted through the communication line 122 to the seat control unit110. In such a configuration, the seat control unit 110 may beconfigured to use this temperature signal to generate the controlsignals transmitted to the backrest control unit 120. In yet anothermodified embodiment, the control unit 120 for the backrest 34 may beoperatively connected directly to the input device 106 in a mannersimilar to that described above for the control unit 110 for the seat32. An example of such an embodiment will be described in more detailbelow with reference to FIG. 7. It should also be appreciated that thecontrol unit 120 for the backrest 34 may be operatively connected to thepower source 114 and the ground source 116 through the communicationline 122.

In the above description, the control units 110, 120 are described asbeing associated with the “back” or “seat” cushion. In modifiedembodiments, it should be appreciated that the features of the back andseat controllers may be reversed. That is, the backrest control module120 may be configured to interpret the signals from the user inputdevice 106 and to control the seat control module. However, theabove-described arrangement is generally preferred because in mostapplications there is generally more room in the seat cushion 32 forvarious electrical connections that are described above. In still otherembodiments, the features of the back and seat controllers may beapplied to different zones of a seat, such as, for example, a top andbottom portion of a backrest. In other embodiments, the features of theback and seat controllers may be applied to different zones of anoccupant area that are to be thermally conditioned, such as, forexample, back and rear seat assemblies or left and right seatassemblies.

In a preferred embodiment, the backrest control unit 120 and/or the seatcontrol unit 110 are generally coupled to the other components of theirrespective thermal modules 92A, 92B and, more preferably, disposedsubstantially within the same housing or protective casing 130 whichcontains the thermoelectric device 94A, 94B and fluid pumps 102A, 102B.FIG. 5 is an illustration of an exemplary cushion thermal unit 92B,which includes a casing 130 that generally surrounds the thermoelectricdevice 94B and fluid pump 102B. The casing 130 preferably also surroundsthe seat control module 110. Electrical wires 132 are operativelyconnected to the seat control module 110 and extend through an opening134 in the casing 130. In the illustrated embodiment, the electricalwires 132 provide the operational connection to the input device 106,power source 114, ground source 116 and/or engine control unit 118. Anelectrical connector (not shown) may be provided at one end of theelectrical wires 132 for providing a convenient connection point. Theelectrical wires may be positioned within a protective tube 138 to formwhat is often referred to in the art as a “pig tail.”

With continued reference to FIG. 5, another set of electrical wires 140may be used to form the communication line 122 between the seat controlunit 110 and the backrest control unit 120. These electrical wires 140preferably also extend from an opening in the casing 130. These wires140 may be positioned within a protective tube 141 to form a “pig tail.”The electrical wires 140 may also provide the connection between thebackrest control module 120 and the power source 114 and ground source116.

The above described embodiments have several advantages. For example,there are no physically separate independent controllers for controllingthe back and seat thermal modules 92A, 92B as is typically found in theprior art. This reduces the amount of space required by the climatecontrol system 36 and reduces the complexity of the overall systemdesign. Advantageously, the system 36 also requires fewer connectionsbetween various components. As described above, the prior art oftenrequired seven or more electrical connections that extend between theintermediate controller and the thermal modules 92A, 92B. Theillustrated embodiment significantly reduces the number of theseconnections, thereby decreasing the complexity of the system, whichreduces installation time and saves space.

FIG. 6 illustrates a climate control system 150 which is configured tocontrol the climates of two seat assemblies 152, 154. As shown, thesystem 150 includes a back and seat thermal modules 92A, 92B asdescribed below for each seat. The seat thermal modules 92B of each seatare operatively connected to an input device 106′, which may includeappropriate user interface such that the user may select the desiredclimate control for each seat. Those of skill in the art will recognizethat the above-described system may be expanded to three, four or moreseats and/or seats of different configurations and/or having more thantwo thermal units associated with each seat.

FIG. 7 illustrates a modified embodiment of a climate control system36′. In FIG. 7, like elements to those shown in FIG. 4 are designatedwith the same reference numbers used in FIG. 4. In addition, onlycertain elements of the climate control system 36′ will be described indetail below. For those elements not described in detail, reference maybe made to the previous detailed description of those elements.

As with the embodiment shown in FIG. 4, the climate control system 36′includes a user input device 106 through which the user of the climatecontrol system 36′ can provide a control setting or set mode for theclimate control system 36′. As will be explained below, in thisembodiment, the user input device 106 is operatively connected to boththe seat control module 110 and the back control module 120′.

The seat control module 110 is operatively connected to the pumpingdevice 102B and the thermoelectric device 94B. In addition, atemperature sensor 112 is provided to measure the temperature of thefluid conditioned by the thermoelectric device 94B. The temperaturesensor 112 is operatively connected to the seat control module 110. Theseat control module 110 is preferably also operatively connected to apower source 114 and a ground source 116 and includes an appropriatepower control unit to provide sufficient electrical capacity to operateall of the aforementioned devices (92B, 94B, 112) of the seat thermalmodule 92B. The seat control module 110 may also be operativelyconnected to a vehicle control device 118 that indicates whether thevehicle's ignition has been turned on. As described above with referenceto FIG. 4, the seat control module 110 preferably also has a controllerthat is configured to receive the occupant inputs from the input device106 and the temperature information from the temperature sensor 112.From this information, the seat control module 110 can make adjustmentsto the operation of the thermoelectric device 94B and the fluid pump102B according to a predetermined logic designed to ensure occupantcomfort and to protect against system damage.

As mentioned above, in this embodiment, the back control unit 120′ isalso operatively connected to the user input device 106. The backcontrol module 120′, in turn, is operatively connected to a pumpingdevice 102A and a thermoelectric device 94A. In addition, a temperaturesensor 124 may be provided to measure the temperature of the fluidconditioned by the thermoelectric device 94A. The temperature sensor 124is operatively connected to the back control module 120′. The backcontrol module 120′ is preferably also operatively connected to thepower source 114 and the ground source 116 and includes an appropriatepower control unit to provide sufficient electrical capacity to operateall of the aforementioned devices (92A, 94A, 124) of the back thermalmodule 92A. As with the seat control module 110, the back control module120′ preferably has a controller that is configured to receive theoccupant inputs from the input device 106 and the temperatureinformation from the temperature sensor 124. From this information, theback control module 120′ makes adjustments to the operation of thethermoelectric device 94A and the fluid pump 102A according to apredetermined logic designed to ensure occupant comfort and to protectagainst system damage.

In a preferred embodiment, the backrest control unit 120 and/or the seatcontrol unit 110 are generally coupled to the other components of theirrespective thermal modules 92A, 92B and, more preferably, disposedsubstantially within the same housing or protective casing whichcontains the respective thermoelectric device 94A, 94B and fluid pumps102A, 102B.

In one embodiment, the back control module 120′ and the seat controlmodule 110 are substantially similar such that the thermal modules 92A,92B are also substantially similar. Such an arrangement allows for thesame type of thermal module to be used for both the seat and backcushions 32, 34, while consequentially reducing costs associated withinventory and production as compared to a system that utilizes twodifferent types of thermal modules. In addition, as with the embodimentof FIG. 3, there are no physically separate independent controllers forcontrolling the back and seat thermal modules 92A, 92B as is typicallyfound in the prior art. This reduces the amount of space required by theclimate control system 36′ and reduces the complexity of the overallsystem design. Advantageously, the system 36′ also requires fewerconnections between various components. As described above, the priorart often required seven or more electrical connections that extendbetween the intermediate controller and the thermal modules 92A, 92B.The illustrated embodiment significantly reduces the number of theseconnections, thereby decreasing the complexity of the system, whichreduces installation time and saves space.

To assist in the description of the disclosed embodiments, words such asupward, upper, downward, lower, vertical, horizontal, upstream, anddownstream have and used above to describe the accompanying figures. Itwill be appreciated, however, that the illustrated embodiments can belocated and oriented in a variety of desired positions.

Although the foregoing description of the preferred embodiments hasshown, described, and pointed out certain novel features, it will beunderstood that various omissions, substitutions, and changes in theform of the detail of the apparatus as illustrated, as well as the usesthereof, may be made by those skilled in the art without departing fromthe spirit of this disclosure. Consequently, the scope of the presentinvention should not be limited by the foregoing discussion, which isintended to illustrate rather than limit the scope of the invention.

1. A device for thermally conditioning and moving a fluid to a climatecontrolled seat assembly, comprising: a thermoelectric device to convertelectrical energy into thermal energy producing a temperature change inresponse to an electrical current being applied thereto; a fluidtransfer device to produce a fluid flow that is in thermal communicationwith the thermoelectric device so that the thermal energy generated bythe thermoelectric device is transferred to or from the fluid flow; aprotective casing configured to be positioned within or adjacent theclimate controlled seat assembly, the protective casing defining aninterior space and having an outlet and an inlet through which the fluidflow is directed, the thermoelectric device and the fluid transferdevice being positioned within the interior space of the protectivecasing; a sensor configured to provide a temperature signal that isindicative of a temperature of the fluid flow; a control unit positionedwithin the protective casing and operatively connected to the sensor,the control unit configured to receive a set point signal that isindicative of a desired temperature of the fluid flow, and based uponthe set point signal and the temperature signal, to control thethermoelectric device and the fluid transfer device; and electricalwires connected to the control unit and extending through an opening inthe protective casing.
 2. The device as in claim 1, additionallycomprising a second thermoelectric device to convert electrical energyinto thermal energy producing a temperature change in response to anelectrical current being applied thereto, a second fluid transfer deviceto produce a fluid flow that is in thermal communication with thethermoelectric device so that the thermal energy generated by thethermoelectric device is transferred to the fluid flow, and a secondcontrol unit for operating the second thermoelectric device and thesecond fluid transfer device, wherein the second thermoelectric device,the second fluid transfer device and the second control unit aresituated within a second protective casing.
 3. The device as in claim 2,wherein the control unit is operatively connected to the second controlunit and the control unit is configured to at least partially controlthe second thermoelectric device and the second fluid transfer devicebased upon the set point signal and the temperature signal.
 4. Thedevice as in claim 2, in combination with a seat assembly, the seatassembly comprising a backrest portion and a seat portion.
 5. The deviceas in claim 4, wherein the backrest portion includes a firstdistribution system in fluid communication with the first fluid transferdevice and the seat portion includes a second distribution system influid communication with the second fluid transfer device.
 6. A methodfor thermally conditioning an area adjacent to a seat assembly,comprising: transmitting an input signal from an input device to a firstcontrol unit of a first thermal module, the first thermal modulecomprising an outer housing enclosing an interior space, the firstcontrol unit being positioned within the interior space; controlling thefirst thermal module based at least in part upon the input signal todeliver thermally conditioned air to a first portion of a seat assembly;and transmitting a control signal from the first control unit of thefirst thermal module to a second control unit of a second thermal moduleso as to control the second thermal module and deliver thermallyconditioned air to a second portion of the seat assembly based at leastin part upon the input signal from the input device; wherein the firstthermal module comprises a thermoelectric device and a fluid transferdevice, the thermoelectric device and the fluid transfer device beingpositioned within the interior space of the housing; and furthercomprising coupling the housing to the seat assembly; wherein the firstcontrol unit is configured to control at least one of the thermoelectricdevice and the fluid transfer device based in part on the input signalfrom the input device.
 7. The method as in claim 6, additionallycomprising sensing a temperature of thermally conditioned air that isdelivered to the first portion of the seat assembly.
 8. The method as inclaim 7, additionally comprising controlling the first thermal modulebased at least in part upon the sensed temperature of thermallyconditioned air that is delivered to the first portion of the seatassembly.
 9. The method as in claim 6, additionally comprising sensing atemperature of thermally conditioned air that is delivered to the secondportion of the seat assembly.
 10. The method as in claim 9, additionallycomprising transmitting the sensed temperature of thermally conditionedair that is delivered to the second portion of the seat assembly to thesecond control unit.
 11. The method as in claim 10, additionallycomprising transmitting a signal regarding the sensed temperature ofthermally conditioned air that is delivered to the second portion of theseat assembly to the first control unit, the transmission of such signalbeing configured to occur through at least one electrical wire, theelectrical wire electrically connecting the first control unit to thesecond control unit.
 12. A self-contained thermal module configured foruse with a climate controlled seat assembly, comprising: a housinghaving an enclosed interior space, the housing comprising a fluid inletand a fluid outlet; a thermoelectric device; a plurality of heatexchange members in thermal communication with the thermoelectricdevice; a fluid transfer device configured to transfer a fluid from thefluid inlet to the fluid outlet at least partially through the heatexchange members in order to selectively heat or cool the fluid; asensor adapted to provide a temperature signal indicative of atemperature of the fluid that has been transferred through the heatexchange members; and a controller operatively connected to the sensor,the controller configured to control at least one of the thermoelectricdevice and the fluid transfer device control based at least in part onthe temperature signal; wherein the thermoelectric device, the heatexchange members, the fluid transfer device and the controller aresituated within the enclosed interior space of the housing; wherein theself-contained thermal module can be installed in a climate controlledseat assembly without the need for an independent control unit that isphysically separated from the housing.
 13. The thermal module of claim12, wherein the housing further comprises an opening, the opening beingconfigured to connect at least one wire from outside the housing to thecontroller.
 14. The thermal module of claim 13, wherein the wire iselectrically connected to a power source, the sensor or a user inputdevice.
 15. The thermal module of claim 12, wherein the fluid outlet isconfigured to be placed in fluid communication with at least one fluiddistribution member of a climate controlled seat assembly.
 16. A methodof adapting a seat assembly with a temperature control device, themethod comprising: providing a seat assembly having a seat back portionand a seat bottom portion, at least one of the seat back portion and theseat bottom portion comprising a fluid distribution member configured toreceive fluid and generally distribute it toward a seated occupant;securing a first self-contained thermal module to the seat back portionor the seat bottom portion, said first thermal module comprising: ahousing having a fluid inlet and a fluid outlet; a thermoelectricdevice; a fluid transfer device configured to transfer a fluid from thefluid inlet to the fluid outlet past the thermoelectric device toselectively heat or cool the fluid; a controller configured to controlat least one of the thermoelectric device and the fluid transfer devicecontrol; wherein the thermoelectric device, the fluid transfer deviceand the controller are positioned within an interior space of thehousing; and wherein the housing comprises an opening for routing atleast one electrical connection therethrough; providing a user inputdevice configured to permit a user to select a desired temperaturesetting; coupling the first thermal module to the seat assembly; andelectrically connecting the controller of the first thermal module tothe user input device and a power supply using wire connections routedthrough the opening of the housing; wherein the first thermal module canoperate without the need of an independent control unit that isphysically separated from the housing.
 17. The method of claim 16,further comprising providing a sensor in data communication with thecontroller of the thermal module, the sensor being adapted to provide atemperature signal indicative of a temperature of the fluid that hasbeen transferred past the thermoelectric device.
 18. The method of claim16, further comprising securing a second self-contained thermal moduleto one of the seat back portion and the seat bottom portion, the secondthermal module being configured to operate without the need of anindependent control unit.
 19. The method of claim 18, wherein the secondthermal module comprises a second controller that is in datacommunication with the controller of the first thermal module.
 20. Aclimate controlled seat assembly comprising: a seat back portion and aseat bottom portion; a first thermal module comprising: a protectivehousing separate and independent from the seat back portion and the seatbottom portion, the protective housing having a fluid inlet and a fluidoutlet, the protective housing defining an interior space; athermoelectric device; a fluid transfer device configured to transfer afluid from the fluid inlet to the fluid outlet through or near thethermoelectric device to selectively heat or cool the fluid; and acontrol module configured to control the thermoelectric device and thefluid transfer device depending at least partially on a temperaturesignal, the temperature signal being based on the a temperature ofthermally conditioned fluid that has been transferred through or nearthe thermoelectric device; wherein the thermoelectric device, the fluidtransfer device and the control module are at least partially situatedwithin the interior space of the protective housing; and a fluiddistribution member having an entry passage, the entry passage being influid communication with the fluid outlet of the first thermal module;wherein the fluid distribution member is positioned within at least oneof the seat back portion and the seat bottom portion of the seatassembly, and wherein thermally conditioned fluid entering the entrypassage of the fluid distribution member is configured to be distributedtoward a seated occupant of the seat assembly; wherein the first thermalmodule can be installed in the seat assembly and can be properlyoperated without the need for an independent control unit that isphysically separated from the protective housing.
 21. The seat assemblyof claim 20, further comprising a user input device, the user inputdevice being operatively connected to the control module of the firstthermal module.
 22. The seat assembly of claim 20, further comprising asecond thermal module, the second thermal module configured to providethermally conditioned fluid to a different part of the seat assembly.23. The seat assembly of claim 20, wherein the thermoelectric devicecomprises a Peltier circuit and the fluid transfer device comprises aradial fan.